I NTERNSHIP REPORT AT - foodscienceuniverse.com REPORT... · Noon dairies are the ... h‐quality Hy r dairy pro tured and ... ents are inc on lab control lab B ological lab

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1

2

Sr.# Outlines

1. Acknowledgement, Abstract

2. Introduction

3. International Certifications

4. Departments

5. Milk collection system

6. Milk Reception

7.

Test Performed in Reception Lab Organoleptic tests Qualitative tests

Quantitative Tests Adulteration tests

8. Dairy processing

9.

Pasteurization section

Flow diagram of pasteurization Pasteurization step

Standardization and toning

10. Powder plant

11.

Butter Section

Flow diagram of ghee and butter White Butter Yellow Butter Salted Butter

Slightly Salted Butter Shelf life

12.

Cheese

Cheddar Cheese Spicy Cheese

Mozzarella Cheese

13. UHT Section

3

UHT flow diagram UHT Process Steps Aseptic Packaging

Capacity

14. UHT Lab Analysis

15. Tests For Insuring Packaging Safety

16. Keeping quality lab

17. Microbiology lab

18.

CIP (Cleaning In Place) Section

Function Of Various Cleaning Agents In CIP

C.I.P STEPS

19. Technical Data sheet

20. Suggestions

4

ACKNOWLEDGEMENT

In the name of Allah who is the most merciful and beneficial. All and every kind of praises is

upon Allah Almighty, the strength of universe, ever help in darkness and difficulties. All and

every kind of respect to Holy Prophet Muhammad (PBUH) for being a unique,

comprehensive and everlasting source of guidance and knowledge for humanity

I am also thankful to the general management of NURPUR, MALIK IZHAR HUSSAIN , all the

Managers, officers and employees of Noon Pakistan Limited for their co‐operation and

support during my internship.

I would like to pay sincere thanks to my Director Dr. Sarfraz Hussain, Institute Of Food

Science and Nutrition, UOS of his sincere cooperation during my internship.

Words do not come easy for me to mention the feelings of humble obligations towards my

sweetest and affectionate parents who have been models of human values for me, who

always encouraged me throughout my career and remember me in prayers and always

wished to see me glittering high on the skies of the success.

5

ABSTRACT

I did my internship in Noon group of industries. This report covers the activities and

responsibilities that I performed during my internship at Noon diaries. Noon dairies are the

National Company with a burning passion to take on the national market. In the culture of

dairy industries Nurpur has distinguished place in Pakistan.

The report starts with the prologue of the company, the intention, its products, and its

structure covering all the departments, furthermore it includes information about labs and

processing section of different products. The assignment was to work with a professional

organization to get professional experience of the office routines and the working of the

organization at the initial level. I worked there as an intern for the 2 months. I learned a lot

of things related to its product and there production. I leant many other things that will help

me a lot when I will start my professional career. I was assigned to work from reception lab

where I performed practices related to raw milk which includes qualitative analysis,

quantitative analysis and adulteration tests on milk to check the quality of milk in order to

maintain the high quality of milk and products. Then I was assigned in Quality control lab in

Chemical Lab. All the analysis regarding physical and chemical properties of line and finished

product were performed. Then I visited different sections of processing area started from

processing pasteurized milk and then processing of butter, Desi ghee, cheese section UHT

milk and processing of fruit drinks and nectars. Then I learnt to testify UHT products in UHT

Lab. Then I started my work in Microbiological Lab In order to ensure a microbiologically

safe product the Quality Assurance department has a well‐established Microbiological

section for analysis of line and finished product. Here I performed tests on different dairy

products juices to ensure microbiologically safe products.

All these areas are hygienically clean. They are properly sanitized regularly. Members of

processing section wear lab coats and cap to maintain hygienic conditions.

Noon Pak

Dynasty

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10

3. Production department;

In this, these departments are included

Reception

Pasteurization

Standardization

Ghee & butter making

Milk powder production

UHT

UHT milk

UHT drinks & nectars

UHT cream

UHT chai mix

Packaging of jam & marmalades

Cheese making

4. Maintenance department

Electrical

Mechanical

Utilities

Maintenance of compressor

Ammonia compressor

Ice water compressor

Air compressor

Maintenance of boilers

5. Milk Procurement Department (MPD)

The Milk Procurement Department (MPD) has responsibility to collect the milk from the area

& maintain the supply the milk in the adequate quantity.

MPD ensure and streamline the regular supply of milk according to quality standards and

budget requirements of NOON DAIRIES.

11

MILK RECEPTION AND

QUALITY CONTROL LAB

12

MILK COLLECTION SYSTEM

According to following system the collection of milk in NOON DAIRIES takes place,

Farmer Mini Supplier Contractor

↓ ↓ ↓

VMC VMC VMC

↓

Sub Center

↓

Main Center

↓

Factory

VMC is the abbreviation of Village Milk Collection Centers. In VMC’s from Farmers, Mini

suppliers and Contractors the collection of milk takes place. These VMC’s provide milk to

Sub Milk Collection Centers. From these Sub Milk Collection Centers the milk is providing to

Main milk Collection Centers like Bhera, Mandi Bhawaldin, and Sahiwal Centers etc. These

main centers have the chilling facilities. In these main centers the basic analysis of milk takes

place for checking their quality. After that the good quality milk is transferring to the

Factories via Milk Collection Tankers.

MILK RECEPTION

When the tanker enters into the NPL premises, a token is a lot to driver that has following:

1 Name of the supplier/Area.

2 Number of the tanker.

3 Token # allotted by the gate keeper.

13

4 Anything attached to the truck e.g. Tire, bag.

Then the truck goes to the parking area from where sample is taken by the Reception Lab

technician. Then reception lab technicians perform the tests needed, if the results are ok,

milk is graded as A and B, the stamp (ACCEPTED) is marked on the token, while C grade milk

is rejected then the accepted truck goes to the Weigh Bridge where it is weighed. Then truck

comes to the receiving area where finally the reception of the milk takes place by the

centrifugal pumps, chilled at 10°C and is stored into the silos. Then the empty truck again

goes to the weigh Bridge & again weighed & finally goes out of the NPL.

Weight of milk = Total Weight ‐ Empty tanker weight

Volume in liters of milk = weight in kilogram /specific gravity of that milk

Reception Lab Activities

Reception lab is a place where the composition of milk and milk adulteration is usually

determined by a number of tests on arrival and adulterated milk is not accepted.

A) Sampling of Raw Milk

Milk is thoroughly mixed with the plunger for 1‐2 minutes, then the sampling is done by lab

technician with the help of sampler, called knoppy.

Types of Sample:

Composite Sample:

Mixed sample is taken from all the portions of a tanker in equal amount. The amount of

composite sample is 1000ml.

Separate Sample:

Sample taken from a single portion of the tanker is called separate sample. The amount of

separate sample is 1000ml.

14

TESTS OF MILK IN QUALITY ASSURANCE LAB

Reception Lab

In reception lab 4 types of tests are performed which are given below;

1. Organoleptic tests

2. Qualitative tests

3. Quantitative tests

4. Adulteration tests

Quantitative Tests:

o Salt test

o Fat test

o Lactometer reading

o Solid not fat (SNF)

o Protein test

Adulteration Tests It includes determination of

o Glucose

o Sucrose

o Detergent

o Starch

o Urea

o Sorbitol

o Boric acid test

o Formalin test

15

ORGANOLEPTIC TESTS

Taste

Check taste of milk. It should not give odd taste.

Smell

Take in the aroma of milk. It should be of milky odour.

Appearance

Milk should be of uniform color and texture.

QUALITATIVE TESTS

1- To check temperature of milk

Apparatus:

Glass Thermometer, glass beaker

Procedure

Thoroughly mix the sample to get representative sample.

Dip calibrated thermometer bulb in it in such a way that it should not touch the

bottom and walls of beaker.

Allow to stay thermometer in sample for a time that no more move up and down.

Note the reading of thermometer.

Temperature of milk should be between 4 - 6 degrees Celsius.

Precaution:

The thermometer should be clean and properly calibrated.

2- pH: pH of milk is checked by dipping pH meter in the milk.

For raw milk the best pH is between range of 6.60 ‐ 6.80

16

Precaution:

The pH meter should be clean and the probe should not touch walls of beaker or its bottom.

3- Clot on boiling test:

Scope:

It is done to check the quality of milk for its fitness for processing.

Apparatus

Test tube, spirit lamp, pipette, test tube holder.

Procedure:

Take 4‐5ml milk sample in test tube with pipette.

Heat the milk on burner spirit lamp to boiling point.

Result:

After boiling if test tube is clear note it as "‐ve" and if clots appear then note it as "+ve".

4‐ Determination of Acidity

Apparatus:

Pipette, beaker and burette

Procedure:

Take 9ml milk sample in beaker with help of pipette.

Add 3‐4 drops of 1% phenolphthalein solution, as indicator.

Slowly add 0.1 NaOH from burette drop by drop with constant stirring of sample in beaker.

Titrate till light pink end point.

Note the burette reading and multiply with 0.1 to get acidity

17

5- Alcohol precipitation test:

Scope:

To Check the Heat Stability of milk during heat treatment.

Apparatus:

Test tube, pipette

Reagents:

Ethanol 68%

Procedure:

Take 2ml milk sample with the help of pipette in a clean dry test tube.

Add 2ml of ethanol in test tube.

Invert the test tube 2‐3 times.

Observe the grain or precipitate formation along the walls of the tubes

Results:

If precipitation occurs, then record the test as "+ve"

18

QUANTITATIVE TESTS

1‐ Determination of Fats in Milk

Apparatus:

Butyrometer, pipette (10.94mm), Butyrometer stopper, Butyrometer stand, Centrifuge

machine, Auto measure,

Reagents:

Sulphuric Acid, Iso‐Amyl Alcohol

Procedure:

Warm milk sample up to 40 °C and thoroughly mix it.

Cool it at 20°C.

Measure out 10 ml of sulphuric acid in a butyrometer.

Add 10ml of milk and 1ml of isoamyl alcohol into butyrometer.

Insert stopper into the butyrometer.

Mix the content well by inverting the butyrometer several times.

Place butyrometer in centrifuge machine (1100 ppm for 3 min) for raw milk.

And 10 min in case of homogenize milk.

Note the fat column in the neck of butyrometer.

Express the result in percentage of fat in milk.

19

2‐ Determination of %Salt (NaCl) in Milk: Apparatus:

Burette, pipette, beaker (100ml), flask (1000ml)

Reagents:

0.1N silver nitrate solution,

10% potassium chromate solution

Procedure:

Take 9ml well mixed sample of milk in a 100ml beaker with pipette.

Add 3‐4 drops of potassium chromate solution being used as indicator.

Titrate the sample against 0.1N AgNO3.

Before titration make sure that level of 0.1N AgNO3 is at "0" mark.

Add 0.1N AgNO3 solution drop by drop from burette until light brown color appears.

This is the end point and no more AgNO3 should be added.

Note reading from burette.

Calculate the percentage as below:

Number of ml of N/10 AgNO3 solution used multiply by 0.065 = %salt

20

3‐ Lactometer Reading

Apparatus:

Cylinder

Procedure:

Heat the sample to 40°C and then is cooled down at 20 °C.

The cylinder and lactometer are rinsed with milk, cylinder has capacity of 300‐350 ml. now

pour milk in cylinder and then place lactometer.

Then add little more milk to remove the foam and then check the reading. If temperature of

milk is 20 degrees Celsius then reading is correct but if increases or decreases then add or

minus 0.2per each degree rise or fall in temperature.

For raw milk LR reading should be in range of 19‐28.

SNF Calculations:

For SNF calculations we require to know the values of LR and FAT.

We can find SNF of milk by putting values in the formula

(LR/4+0.72)+0.22 multiply by FAT%)

21

4) Determination of Protein

Apparatus:

Pipette, Stand, Beaker, Burette

Reagents:

0.1N NaOH, Phenolphthalein, Formalin

Procedure:

Take 10ml milk in beaker.

Add 1ml Phenolphthalein indicator.

Titrate it against 0.1N NaOH

Then note reading as V1 then add 2ml of formalin and stay for 5 minutes.

Then titrate against 0.1 N NaOH (note reading for 0 – V1).

Then take 10ml distilled water and add 1ml phenolphthalein and titrate against 0.1 N

NaOH and note it as V2.

Formula:

V1‐V2*1.94 protein

If on the basis of SNF is calculated by

Answer of above multiply by 9/SNF of milk.

22

ADULTERATION TESTS

1‐ Detergent Determination in Milk

Purpose:

To determine the adulterations in the milk like carbonates and bicarbonates.

Apparatus:

Petri dish, Pipette

Reagents:

10% Rosalic Acid, 95% Ethyl Alcohol

Procedure:

Take 5ml of milk sample in a clean and dry pipette.

2) Then add 5ml of 95%Ethyl Alcohol in it.

3) At last 2‐3 drops of rosalic acid in it.

Result:

Positive Test:

If the color is blue then test is positive.

Negative Test:

If the color remains unchanged like the color of Rosalic acid then

the test is negative.

23

2‐ Starch Determination

Apparatus;

Pipette, Petri Dish, Water bath, beaker

Reagents:

0.1 N Iodine: Weigh 12.69g Iodine and add sufficient quantity of ethanol to make total

solution 1000ml.

Procedure:

Take 4‐5 ml of milk sample in the clean and dry test tube.

Warm the milk sample near to boil in the water bath.

Pour the milk sample in the Petri dish.

Then add 2‐3 drops of Iodine in the milk sample.

Shake the Petri dish slowly and gently.

Carefully observe the color of Petri dish.

Results:

Positive Test:

If the black or dark blue spots appear the test is positive.

Negative Test:

If no black spots or precipitations then test is negative.

3) Glucose Determination in Milk

Apparatus:

Glucose Strip, Beaker

Procedure:

Take the milk sample in the beaker.

24

Dip the Glucose strip in the beaker containing the milk sample.

Observe carefully the color of the glucose strip.

Result:

Negative:

If color is yellow then test is negative.

Normal:

If color of the strip changes to light green then glucose contents are in

normal range.

Positive:

But if color is highly green then it is positive.

Urea Determination in Milk

Appratus;

Volumetric flask, Test Tube, Pipette

Reagents:

Phenol Red

Urease 0.2%: Take 0.2g urease and 10 ml of K2HPO4 (10% in distilled water) and add

sufficient quantity of distilled water to make total solution 100 ml.

Procedure:

Take the 2ml mixed milk sample in the test tube.

Add 2ml urease solution in the test tube containing the milk sample.

Add 0.2ml phenol red in the test tube containing the milk sample and urease

solution

Incubate the test tube at 40‐45˚C in the water bath for 10 min.

Observe carefully the color of the test tube contents after incubation.

Result: Negative:

25

If color of the test tube contents does not change (i.e. if it retains the

previous color) then test is negative.

Positive:

If color of the test tube contents changes from orange to pink then it is

positive.

1‐ Sorbitol Determination of Raw Milk

Apparatus:

Pipette, Test Tube

Reagents:

Reagent A (NaOH), Reagent B (Ferrous Sulphate)

Protocol:

Take 1 ml of milk sample in the clean test tube at 15‐ 20˚C.

Then add 1ml of reagent A and 2ml of reagent B in the test tube containing milk

sample.

Shake well and stay for 3 min.

Carefully examine color, sticking and settling of test tube contents.

Results:

Positive Test:

Light yellow color

Sticking with wall of test tube.

Settling of viscous solution at the bottom of test tube

26

5‐ Sugar(Sucrose) Determination in Raw Milk

Apparatus:

Pipette, Water bath, Test tube, Pipette 1ml,

Reagents:

HCl

Naphthol 10%: Dissolve 10g naphthol in ethanol and add sufficient quantity of

ethanol to make total solution 100ml.

Procedure:

Take 0.5 ml of milk sample in the clean and dry test tube.

Then add 3ml of conc. HCl in the milk sample

Then add 2‐3 drops of naphthol10% in the test tube.

Place the test tube in the water bath for 10 sec.

Let the test tube to cool down.

Carefully observe the color of test tube contents.

Results:

Positive Test:

If the violet deep color appears then the test is positive.

FINAL PRODUCTS TO BE EVALUATED IN QUALITY CONTROL LAB.

o Milk Powder: It includes;

I. Skimmed milk powder.(SMP)

II. Full cream milk powder.(FCMP)

27

1‐ Acidity of Milk Powder

Purpose:

To determine titratable acidity in dry milk powder.

Apparatus:

Balance (sensitivity = 0.01 gram), Burette (0‐25ml),Stirring rod of solid glass, Pipette, Glass

beaker (100 ml).

Reagents:

1% Phenolphthalein solution, 0.1 N NaOH Solution.

Procedure:

Using mixer dissolve in 100 ml of distilled water.

o 10 grams in case of skim milk powder.

o 13 grams in case of whole milk powder.

Allow the sample to stand for approximately 1 hour, and then stir gently.

Pour 17.6ml of sample solution using a pipette into a 100ml beaker.

Add few drops of phenolphthalein and titrate with 0.1N NaOH solution until a faint

pink colour persists for 30 seconds.

Note and record the volume of NaOH used and calculate the titratable acidity as

Acidity (as % lactic acid) = ml of 0.1N NaOH used / 20

2‐ Fat Test – Milk Powder

Purpose:

Apparatus:

Butyrometer (0‐4% scale for SMP & 0‐35% for FCMP), Butyrometer stopper, Butyrometer

stand, Weighing balance, Pipette, Centrifuge Machine.

28

Reagents:

Sulphuric acid (density = 1.820 ‐ 1.830 gm/ml) clean, colourless, free from fat.

Iso‐ Amyl alcohol (density = 0.811 gm/ml) free from water, acid and fat.

Procedure:

Pour successively into Butyrometer, 10 ml of sulphuric acid.

Add 2 ml of distilled water, Add 2.5 grams milk powder sample 1 ml of Iso Amyl

Alcohol.

Stopper the Butyrometer and mix well the contents by shaking.

Spin in centrifuge for 10 minutes.

After centrifugation, take butyrometer out of the centrifuge machine.

Note the fat column in the neck of the butyrometer.

3‐ Moisture Test – Milk Powder

Purpose:

To determine moisture percentage in milk powder with the help of moisture analyzer

Apparatus:

Moisture analyzer, Aluminum boat, Spoon.

Procedure:

Set the temperature of moisture analyzer to 90 °C and timer to 6 minutes.

Take 2 ‐ 4 grams of sample in aluminum boat place it on the balance in the moisture analyzer.

Distribute sample evenly over the entire aluminum boat for quick evaporation.

Close the chamber of moisture analyzer.

Push ON/OFF switch to set the equipment in operation.

After specified time, screen will display the reading showing percent loss in initial

weight (i.e. moisture percentage).

29

4‐ Bulk Density – Milk Powder

Purpose:

To determine the bulk density of dry milk powder.

Apparatus:

Balance (sensitivity 0.1 gram),Brass cylinder with detachable top, volume of cylinder

should be exactly 100 cubic centimeter, Spatula.

PROCEDURE:‐

Weight the cylinder without the top.

Put the top on the cylinder and fill up to the rim with Powder using a spoon.

Rotate BD machine 25 times, remove the top and scrap off Powder with the help of a

spatula.

Weigh the cylinder, the weight of the powder indicates Powder Bulk Density.

Powder Bulk Density = Weight of the powder / 150

5‐Solubility Index‐ Milk Powder

Purpose: To determine the solubility index (ability to dissolve in water) of dry milk powder.

Apparatus:

Balance (sensitivity 0.1 gram), Solubility index tubes (15 ml), Centrifuge machine

Procedure:

Weigh out 10 grams of Skim Milk Powder or 13 grams of Whole Milk Powder and

transfer to

100 ml of distilled water at 24 °C in a 500ml beaker.

Mix the contents, wait for 15 minutes.

Fill in solubility index tubes with samples and place them in centrifuge machine for 5

minutes.

30

After first centrifugation, take out tubes ,drain OFF sediment free liquid carefully.

Fill in the tubes with distilled water up to the marked point and disperse the

sediment in tubes with a piece of wire.

Place the tubes in centrifuge machine for 5 minutes and then check the amount of

sediment in mille liters.

6‐SCORCHED PARTICLES TEST:

Sample is mixed to make 10% solution in distilled water and stayed for 5 minutes.

Then check black particles.

If Black particles present then milk powder is of B‐grade.

If not then it’s A‐grade

o CHEESE ANALYSIS

Types of cheese evaluated in QC lab

1. Cheddar cheese

2. Mozzarella cheese

3. Spicy cheese

4. Green cheese

1. Fat test;

Take 10 ml sulphuric acid in butyrometer (87‐90%)

Then add 2.5g of minced cheese sample

Add amyl alcohol 1ml then volume is raised by adding 3 – 5 ml distilled water

Fit the cork

Then place in gerber machine, its temp is 63‐65ºc and rpm is 1100

Place it 4 mins

31

After this constant fat reading is achieved

2. Acidity test;

3g of minced sample of cheesed is mixed with 10ml distilled water

1 ml of phenolphthalein indicator is added.

This sol is titrated against 0.1 normal NAOH reading is multiplied with 0.3.

3. Salt test;

Take 2.5g of cheese sample and add 9ml distilled water in it with the addition of2‐3 drops of

potassium chromate as an indicator.

Titrate it against silver nitrate.

Final reading is multiplied with 0.234.

End point

Brick red color or yellowish brown color

4. Moisture test; 2.5g of sample is taken.

Wt of empty dish is w1.

Wt of empty + sample is w2.

Place this on oven at 4 hrs at 100ºc,

Then remove it and place it in dedicator for cooling.

Then weight it again.

W3 = wt after drying.

D

DAIR

RY PPROOCEESSIING

3

G,

32

33

MILK PROCESSING

Storage of milk for production lines:

Milk is brought to inner silos or holders from the outer large silos through

pumps to be used for production of dairy products and is stored at less than

10°C.

Raw Milk Silos Capacity

Raw Milk Silo 1 75000 Lt



PASTEURIZATION SECTION

Pasteurization

Introduction

The process of pasteurization was named after Louis Pasteur who discovered that spoilage

organisms could be inactivated in wine by applying heat at temperatures below its boiling

point. The process was later applied to milk and remains the most important operation in

the processing of milk.

Definition:

The heating of every particle of milk or milk product to a specific temperature for a

specified period of time without allowing recontamination of that milk or milk

product during the heat treatment process.

Milk is pasteurized in order to inactivate the enzymes and destroy the pathogenic

microorganisms. The extent of microorganism inactivation depends on the combination of

temperature and holding time .The shelf life of the milk is increased up to 7‐8 days after

pasteurization.. Milk is pasteurized by plate heat exchanger. which has 4 sections i.e.

34

I. Heating section

II. Regeneration 1

III. Regeneration 2

IV. Cooling section

Separator and homogenizer also used to separate and to homogenize the cream

respectively

The following steps take place in the process of Pasteurization:

1)Balance tank:

From the silo milk comes in balance tank through a centrifugal pump. Balance tank have a

central float ball, which controls the quantity of incoming milk by a valve & maintain the

milk level as needed by the process.

2)Filter

Milk comes through the sieve filter passing through centrifugal pump goes to the

Regeneration No.1 (Pump functions to create greater pressure in milk as compared to

the heating media to prevent mixing in case of leakage of gaskets.)

3)Regeneration No.1

By passing through the filter milk goes to regeneration no.1, where the

temperature of the milk is raised to 50‐55oC by regeneration method.

4)Separator

From regeneration no.1 milk goes to separator that will separate the extra butterfat

from the milk in the form of cream and it will also remove the unwanted material in the milk

(Sludge). Separator works at 5400 RPM.

5) Homogenizer

From deodorizer milk goes to homogenizer in which milk is passed through nozzle at high

pressure of 100‐150 bar as a result fat globules are converted into smaller particles

(1micrometer).

35

6) Regeneration No.2

Then the milk goes to regeneration no.2. It is also part of plate heat exchanger (PHE)

in which milk is heated to 65oc.

7) Heating Section:

In the heating section temperature of milk is increased to 88‐90oC with help of hot water.

Flow Diversion Valve:

If temperature of milk is less than 85oC, it will not go towards holding tubes, it is delivered

back to balance tank by flow diversion valve for reprocessing. It is manually operated.

8) Holding Tubes:

Here milk stays for 11‐15 seconds at 88‐90oC, so that enzymes like phosphatase, lipase etc.

are inactivated and microbes are killed.

9) Regeneration no.2

Now milk moves back in regeneration no.2. to warm the incoming cold milk of balance tank.

So in this way energy is conserved. Here temperature of milk drops to 60‐65oc.

10) Regeneration no.1

Pasteurized milk heated the incoming cool milk to save the energy. Here the temperature of

the milk drops to 45‐50oc.

11) Cooling Section:

In cooling section the temperature of the milk drops to 4‐6oc due to chilled water.

Pressure Differential

For contiunuous pasteurizing, it is important to maintain a higher pressure on the

pasteurized side of the heat exchanger. By keeping the pasteurized milk at least 1 psi higher

than raw milk in regenerator, it prevents contamination of pasteurized milk with raw milk in

event that a pin‐hole leak develops in thin stainless steel plates.

Standard

Here the

(adjustm

agitators

milk adju

added to

The Stan

In Stand

want to

Standa

dization & To

e milk is stan

ment of SNF)

s so fat and S

usted to a s

o increase th

ndardization

dardization

o make, is se

rdization Ap

Plate heat

oning:

ndardized ac

) and Toning

SNF of paste

set level fo

e SNF & LR w

Plant:

Plant, milk i

et. The most

pparatus:

t exchanger

ccording to t

g (adjustme

eurized milk

r each prod

while cream

s standardiz

important c

the standard

nt of Fat) a

with cream

duct . The c

m is added to

zed, i.e. the

component o

ds of NOON

always take

, water, mil

condensed (

o fat.

recipe ratio

of the recipe

DAIRIES. Sta

place in the

k powder an

(condensed

of the prod

e is the fat p

3

andardizatio

e silos havin

nd condense

skim milk)

uct which w

ercentage

36

on

ng

ed

is

we

Separat

A separ

Separat

Separat

tor is used fo

rator is a cen

tor also acts

tor’s speed a

or the purpo

ntrifugal dev

as a clarifie

and time of

ose of stand

vice that sep

r.

centrifugatio

ardization.

parates milk

on give requ

into cream a

uired standa

and skim mi

rds of fat in

3

lk.

milk.

37

38

PASTEURIZED MILK PACKING

Pasteurized milk is packed in 1000ml, 500ml volumes in handy and hygienic packaging.

Nurpur Whole Pasteurized Milk has 3.5% Butter Fat and 9% SNF, free from additives. Nurpur

fresh pasteurized milk has been its guarantee quality label for many years.

Process Flow Diagram of Pasteurized Milk Receiving of raw milk

↓

Weighing

↓

Out ← Rejected ↑

← Lab. Sampling and analysis

↓

If Accepted

↓

Reception ↓

↓

Chilling

↓

Raw milk storage

↓

Balance tank

↓

Pre‐ heating 1

50‐55°c

↓

Storage

Cream ← Skim milk / cream separa on

39

↓

Homogenization

100‐150 bars

↓

Pre‐ heating 2

65°c

↓

Pasteurization

(88‐90)°c

↓

Holding section

(88‐90)°c for 11‐15 sec

↓

Regeneration ‐2

(temp. drop upto 60‐65°c)

↓

Regeneration – 1

(temp. drop upto 45‐50°c)

↓

Cooling section

4°c

↓

Storage in

Pasteurized standardized milk in pasteurized milk tank

↓

Packing machine

40

POWDER

PLANT

41

MILK POWDERS There are mainly THREE types of powders produced in powder plant.

Skimmed milk powder (SMP)

Instant skimmed milk powder (ISMP)

Full cream milk powder (FCMP)

There are two powder plants in Nurpur

Old milk powder plant

It has tubular evaporator

New milk powder plant

It has plate heat exchanger double effect evaporator

There are two main sections of powder plant

Evaporation section

Drying section

. Evaporation

The heat-treated milk is then fed into an evaporator. In the evaporator the preheated milk

is concentrated from around 9.0%

Milk is taken in balance tank of evaporator at 5 to10 C with the help of pump. Milk is

then reaches to condenser with the help of flow control valve, through density transmitter

which determine specific gravity of the milk. In condenser heating of milk start and

reaches to41C. In condenser milk is milk is fed in to holding tubes 180sec now the milk is

filtered and then goes to homogenizer at 80 bar pressure and then to 40 bar pressure

Homogenization can be carried out in one or two stages. The pressure of the first stage of

the homogenizer is from about 50 to about 250 bars. . It is important in this case that the

fat part of the milk is completely homogenized together with an appropriate part of the

non-fat solids and water.

42

Drying Section

Condensed milk goes to drying chamber through four nozzles of a spray drier at a

temperature of 155‐190˚C .Spray drying involves atomizing the milk concentrate from

the evaporator into fine droplets .

This is done inside a large drying chamber in a flow of hot air (up to180˚C) using high

pressure nozzles.

Much of the remaining water is evaporated in the drying chamber, leaving a fine powder

of Around 6% moisture. Final drying takes place in a fluid bed in which hot air

Is blown through a layer of fluidized powder removing water to give product with

moisture

Content of 2‐4% the powdered milk leaves the chamber at temperature of 55‐65˚C.

Packaging and Storage

Milk powders are immensely more stable than fresh milk but protection from moisture,

Oxygen, light and heat is needed in order to maintain their quality and shelf life. Milk

Powders readily take up moisture from the air, leading to a rapid loss of quality and

caking or

Lumping.

Milk powder is packed into either plastic bag in bulk. WMPs are often packed under

nitrogen gas to protect the product from oxidation and to maintain their flavor and

extend their keeping quality. Packaging is chosen to

Provide a barrier to moisture, oxygen and light.

In Nurpur WMP and SMP is packed in 25 kg of bags

8°

NEW POW

Full Cr

For over

in marke

obtain es

other mil

Silo+Holder

°C

WDER PLANT

ream Milk

30 years, Nu

t. With 25-2

specially fro

lks. It is pack

13°C

75°C

k Powder

urpur FCMP

28% fat, it m

m butter fat

ked in 25 kg

Wa

78°C

P because of

meets the requ

t plus all the

g bags.

ater Line

6

f its high qua

uired quantit

e same impo

66°C

ality is a larg

ty of essenti

ortant vitami

W L

ge selling bra

ial fatty acid

ins and mine

Cond

L

64°C

58°C

4

and of Nurpu

ds and calorie

erals found i

denser

C

43

ur

es

in

W L

44

Skimmed Milk Powder:

Nurpur is one of the major market shareholders of SMP in Pakistan, mainly because of its

quality. As “Nurpur SMP” has less than 1.5 % Butterfat so Nurpur Skim/Slim Milk has

virtually less fat and cholesterol and very few calories, plus all the same important vitamins

and minerals found in other milks.

Process Flow Diagram of MILK POWDER FC milk/ skim milk in tank

↓ Balance tank

↓ Condenser

↓

Pre- heater -1 ↓

Pre- heater -2 (90-95)ºc

↓ Calendia – 1

↓ Calendia -2

↓ Atomizer

↓

Dryers

↓

↙↘

Cyclone ‐1 cyclone‐2

↘ ↙

Transport system cyclone

↓

Bagging hopper

↓

Final packing

↓

Storage

45

CHEESE & BUTTER

BUTT

Butter is

However

(sweet) b

cream th

is a prod

hygiene,

that has

introduce

by the m

Nurpur is

from the

also body

freely an

creamy t

industria

butters

markets

Spread t

creamy t

Types of

Two Type

i. W

ii. Y

p

TER

essentially

r, it can also

butters are

hat had been

duct of the

bacterial ac

led to the

ed at the en

iddle of the

s one of the

e best fresh

y required e

nd eat fresh

taste that na

l processors

in tubs ava

a range of p

he golden g

aste. You ne

f Butter

es of Butter:

White Butter

ellow Butter

acking

the fat of t

o be made fr

also availab

n allowed to

knowledge

cidifying and

advanced m

nd of the 19

20th centur

leading pro

milk. With

essential fatt

green gras

ature intende

s. Innovatio

ailable unde

premium but

goodness of

ever had it b

:

packed in 1

r packed in 1

he milk. It is

rom acidulat

ble. Well int

stand and s

and experie

d heat treatm

machinery no

9th century;

ry.

oducers of b

80% fat in N

ty acids. Nur

s all year ro

ed. Nurpur b

n is the ma

er the “Nur

tters. Nurpu

Nurpur But

better.

1 Kg and 5 Kg

10 gms, 20 g

s usually ma

ted or bacte

to the 19th

our naturall

ence gained

ment, as wel

ow used. Th

the continu

utter and bu

Nurpur Butt

rpur butter i

ound. That’s

butter is ava

ain focus. P

rpur butter”

r also export

tter and relis

g packing

gms, 50 gms,

ade from sw

eriological so

century but

y. Today's co

d over the y

ll as the rapi

he commerc

uous churn h

utter produc

ter, not only

s made from

s what gives

ailable in con

rimary exam

” brand nam

ts butter to

sh the very

, 100gms, 20

weet cream

oured cream

tter was sti

ommercial b

years in suc

id technical

cial cream s

had been co

cts in Pakista

y you will ge

m cow’s milk

s Nurpur bu

nsumer pack

mples includ

me. In Paki

many count

special delig

00 gms in 1 K

4

and is salted

m and salt les

ll made fro

butter makin

ch matters a

developmen

eparator wa

mmercialize

an, processe

et energy bu

k, which roam

utter the ric

kaging and fo

de the yello

istan, Nurpu

tries.

ght of its ric

Kg and 5 Kg

46

d.

ss

m

ng

as

nt

as

ed

ed

ut

m

h,

or

w

ur

ch

47

PROCESS DISCRIPTION

If the cream is separated by the butter manufacturer, the whole milk is preheated to the

required temperature in milk pasteurizer before being passed through a separator. The cream

is cooled and led to a storage tank where the fat content is analyzed and adjusted to the

desired value, if necessary. The skim milk from the separator is pasteurized and cooled before

being pumped to storage. It is usually destined for concentration and drying

From the intermediate storage tanks, the cream goes to pasteurization at a temperature of

95°C or more. The high temperature is needed to destroy enzymes and micro-organisms that

would impair the keeping quality of the butter.

In the aging tank, the cream is subjected to a program of controlled cooling designed to give

the fat the required crystalline structure. The program is chosen to accord with factors such as

the composition of the butterfat, expressed, for example, in terms of the iodine value which is

a measure of the unsaturated fat content. The treatment can even be modified to obtain butter

with good consistency despite a low iodine value, i.e. when the unsaturated proportion of the

fat is low.

As a rule, aging takes 12 - 15 hours. From the aging tank, the cream is pumped to the churn

or continuous breakdown via a plate heat exchanger which brings it to the requisite

temperature. In the churning process the cream is violently agitated to breakdown the fat

globule, causing the fat to coagulate into butter grains, while the fat content of the remaining

liquid, the buttermilk, decreases.

Thus the cream is split into two fractions: butter grains and buttermilk. In traditional churning,

the machine stops when the grains have reached a certain size, whereupon the buttermilk is

drained off. With the continuous butter maker the draining of the buttermilk is also

continuous.

After draining, the butter is worked to a continuous fat phase containing a finely dispersed

water phase. It used to be common practice to wash the butter after churning to remove any

residual buttermilk and milk solids but this is rarely done today.

Salt is used to improve the flavor and the shelf-life, as it acts as a preservative. If the butter is

to be salted, salt (1-3%) is spread over its surface, in the case of batch production. In the

continuou

aqueous p

After sal

The work

aroma, t

homogen

globular

in proper

whether t

Precise c

The finis

us butter ma

phase, so the

lting, the bu

king of the b

taste, keepin

nous blend

to free fat. W

rly worked

the fat is har

control of com

shed butter is

B

aker, a salt

e effective s

utter must be

butter also in

ng quality,

of butter gr

Water drople

butter. Ove

rd or soft. So

mposition is

s discharged

Butter grain

slurry is add

alt concentra

e worked vi

nfluences the

appearance

ranules, wa

ets decrease

erworked bu

ome water m

s essential fo

d into the pac

Butte

ns and butte

ded to the b

ation is appr

igorously to

e characteris

e and color

ater and salt

in size durin

utter will be

may be added

or maximum

ckaging unit

er Churn

er milk read

butter. The s

roximately 1

ensure even

stics by whic

. Working

t. During w

ng working

e too brittle

d to standard

yield.

, and from th

dy for separ

salt is all dis

0% in the w

n distributio

ch the produ

is required

working, fat

and should

or greasy d

dize the moi

here to cold

ration

4

ssolved in th

water.

on of the sal

uct is judged

to obtain

moves from

not be visib

depending o

isture conten

storage.

48

he

lt.

d -

a

m

le

on

nt.

Removal of bbutter into tr

Flow lin

rolley

e of Butter

4

49

50

CHEESE:

According to the National Dairy Council, "All cheese is made from milk, but different

manufacturing and aging processes are used to produce the array of cheese available today.

Cheese is made by coagulating or curdling milk, stirring and heating the curd, draining off

the whey (the watery part of milk), collecting and pressing the curd, and in some cases

ripening.

Three types of Cheese

1. Cheddar cheese packed in slices with weight of 200gms, and 1000gms while in cakes

with 225gms and 2000gms

2. Cottage cheese packed in cakes with weight of 200gms

3. Spicy cheddar cheese packed in cakes weight 225gms

Rich source of protein especially casein protein deficiency is fulfilled by cheese. Cheddar and

Cottage cheese produced from fresh milk. For making Cheddar cheese first of all Green

cheese is made. Nurpur offers a wide range of delicious cheeses in market. Nurpur’s

deliciously unique Cheddars are slow matured for a superior taste.

They’re made the right way for a fuller flavor and a taste you can trust. All cheeses are made

from fresh pasteurized cow milk, each subject to a different process to ensure unique taste

and presentation.

The basics of cheese making

The process of cheese making is an ancient craft that dates back thousands of years. By

today's standards of industrial technology, the process of cheese making is still a

complicated one which combines both "Art" and "Science" together. The subject of cheese

has been extensively investigated by many research groups in many countries, and in‐depth

information has been reported, for example, by Kosikowski (1982), Scott (1986), Robinson

(1993) and Fox (1993).

Making G

Cheese m

make sur

is then h

bacteria

change a

much fas

to the m

small cu

productio

carefully

the left‐o

drained

slabs are

it is pres

basic me

Green Chees

making capi

re there are

heated and h

(i.e. pasteu

a very small

ster rate and

milk and with

bes, and h

on of lactic a

chosen poi

over liquid,

off and the

e then milled

ssed, and su

thod for ma

Cheese

se from Curd

talizes on t

no antibiot

held at a giv

rization). Sp

amount of

d prepares it

hin a short t

heat is appl

acid from th

nt the curd

which consi

curd grains

d, and salt is

bsequently

aking what is

milk culture

dled Milk

he curdling

ics or harmf

ven tempera

pecial starter

f the milk su

t for the nex

time a curd

ied to star

he starter cu

grains are a

ists of wate

s allowed to

added to pr

packed in v

s known as a

e and renne

Curd

of milk. Fir

ful agents th

ature for a

r cultures ar

ugar into lac

xt stage. Ren

is produced

t a shrinkin

ultures, will c

allowed to f

r, milk suga

o mat togeth

rovide flavor

various sized

a hard‐presse

et addition a

d setting

rst, the milk

hat could aff

short period

re then adde

ctic acid. Th

nnet (mainly

d. The result

ng process

change it int

fall to the bo

r and album

her to form

r and help p

d containers

ed cheese.

nd mixing in

k is carefull

fect the proc

d to destroy

ed to the w

his acidifies

y chymosin)

tant curd is

which, with

to small size

ottom of th

men (now ca

large slabs

reserve the

for maturin

n cheese vat

5

y selected t

cess. The mi

y any harmf

arm milk an

the milk at

is then adde

then cut int

h the stead

ed grains. At

e cheese va

alled whey)

of curd. Th

cheese. Late

ng.That is th

t

51

to

lk

ul

nd

a

ed

to

dy

a

at,

is

he

er,

he

Cuttin

Cookin

Drain

Che

ng the curd

g the curd

ing of whey

eddaring

y

552

Cheese

Vacuu

Salting

e block filling

Pre

um sealing o

after millin

g and prepa

essing:

of Green che

g

ring for pres

eese block

ssing

553

54

Process Flow Diagram of Green Cheese

Pasteurized & → Lab analysis

Standardized Cheese milk

↓

Temp setting

↓

Culture addition

↓

Rennet addition

↓

Ripening

↓

Cutting of coagulum

↓

Cooking

↓

Block cutting at 0.3% acidity

↓

Milling

↓

Salt addition

↓

Cheese block filling & pressing

↓

Storage

↓

Vacuum sealing

↓

Storage for purpose of Green cheese aging at < 10°C

↓

Cleaning of Aged Green cheese block

55

↓

Cutting Of green cheese

↓

Mincing

↓

Cooking and Addition OF additive

↓

Filling Cheddar cheese in moulds

↓

Storage at <10°C

↓

Cutting in small blocks

↓

Slicing

↓

Vacuum packing

↓

Storage at<10°C

Process Flow Chart of Mozzarella Cheese

Pasteurized & Standardized Cheese milk

↓

Heat upto 34˚C

↓

Add Culture & Leave for 30 min.

↓

Rennet addition & Leave for 40 min.

↓

Cutting of coagulum

↓

Cooking 38‐40˚C until pH 5.2

56

↓

Hanged in Cold Store ↓

Milling

↓

Hot Water @90˚C

↓

Chilled Water @ 4˚C for 2‐3 Hrs

↓

Brine 2‐3 Hrs

↓

Packing

Spicy cheese:

It is produced in assume way as cheddar cheese is produced but difference is that when

whole batch of cheddar cheese is produced green chilies are added in it. Green chilies are

grinded and then added according to taste and flavor

Types of cheese Acidity pH

Mozzarella cheese 0.90 5.10

Green cheese 0.80 ‐

Cheddar cheese 0.10 5.40

57

UHT SECTION

58

UHT SECTION

UHT treatment is a process of heating the milk at temperature 137‐140°C to increase the

shelf life by killing the microbes. The product passes through heating and cooling stages in

quick process and then aseptic filling to avoid the re‐contamination of the product.

Ultra High Temperature treated milk products will easily keep for more than three months

outside the refrigerator.

Process Steps of UHT plant with aseptic homogenizer:

1) Balance Tank:

Standerdized milk from silos moves towards the balance tank which controls

the quantity of incoming milk.

2) Booster Pump:

It pumps the milk from balance tank to regeneration #1.

3) Tubular heat exchanger (THE) coil # 1:

Booster pump will sent the milk to THE coil 1 where milk temperature will

raised upto 50 oC by outgoing water whose temperature is upto 75 o C.


Here the milk temperature increases upto 75 oC by the outgoing water whose

temperature is upto 85-90 oC.

5) Deaerator :

Milk enters in deaerator at temp 75oC where all fowl odorous volatile compounds

and vapors are removed.


Here milk temp increases upto 125 oC by water whose temp is upto 132‐135 oC.

7) Tubular heat exchanger (THE) coil # 4 :

Here milk temp rises upto 130 oC by hot water.

59

8) Tubular heat exchanger (THE) coil # 5 :

It is the main heating unit where required temp 137 oC is achieved. Milk is heated by

hot water whose temp is upto 139‐140 oC

9) Holding tube :

Milk is held at temp 137 oC for four secs in holding tubes.

10) Regeneration coil 1 and 2:

Milk temperature starts decreasing in regeneration coils 1 and 2. When milk leaves

regeneration coil 2 its temperature will be 72 oC

11) Homogenizer :

Here homogenization is done to break the fat globule under a pressure of 200 bar in the

1st stage of homogenizatin. In 2nd stage it is done at 50 bar to break the remaining globules.

Here the fat is uniformly distributed in the milk. Here milk temp slightly increase upto 3 oC

due to homogenizer pressure.

12) Regeneration Coil # 3:

Here the temperature of the milk decreases up to 50oc by incoming water.

13) Chilling Section:

Milk in this section is cooled upto 28‐30oC with the help of cold water.

Aseptic Tank Storage: (Al‐ Safe Tank)

These tanks are used to store the UHT milk if it is not delivered to Tetra Pak.

Milk can stay there for 24 hours.

Aseptic Filling:

It is done by Tetra Pak Filling machines.

Packaging of UHT Milk:

Packed in 250ml, 500ml, and 1000ml volumes in Tetra Brik Aseptic Packing

60

UHT PRODUCTS IN NURPUR:

1. NURPUR UHT PLAIN MILK

2. NURPUR DAIRY WHITNER CHAI MIX

3. NURPUR FLAVORED MILK

4. NURPUR DRINKS & NECTARS

5. NURPUR DRINKING YOGURT

Flavored Milk:

Packing in 1000ml volumes in Tetra Aseptic Packing

Flavored Milk is made from the highest quality standardized milk (3.5% fat) and is carefully

formulated and processed to produce an unparallel high quality, great tasting flavored milk.

While using different flavored milk, you will enter in world of flavors.

Flavored milk is a cool way to get in your daily intake of important nutrients such as calcium,

vitamins A and D and minerals like phosphorus, magnesium and zinc; it helps build a strong

body, healthy teeth and bones.

Currently Nurpur is producing six types of Flavored Milk, nutritional fact of some are

Given below;

Strawberry Flavored Milk:

Packed in 250 ml volumes in Tetra Aseptic Packing

Mango Flavored Milk:


Banana Flavored Milk:


Chocolate Flavored Milk:


61

Ice cream Flavored Milk:


Badam zafran Flavored Milk:


Process Flow Diagram of Flavored Milk

Raw milk

↓

Standardization

↓

Pasteurization

↓

Add color & flavor

↓

Homogenization

↓

Ultra heat treatment

↓

Filling

↓

Aseptic packaging

62

Chai Mix (Dairy Whitener)

Process Flow Diagram of Chai Mix

Raw milk

↓

Standardization at 7% fat content

↓

Pasteurization

↓

Homogenization

↓

Transfer to UHT tank

↓

Store in UHT aseptic tank

↓

Aseptic packaging

63

NECTAR & JUICES:

Nurpur is providing three types of nectars which are apple, orange, guava and mango

nectars. These nectars are of high quality, unique tasting with high nutritive value.

Packing of all nectars in 1000ml as well as in 200ml volumes in Tetra Aseptic Packing

Process Flow Diagram of Juices & nectars on UHT flex

Ingredients

Pulp

Color

Stabilizer

Sugar

Water

Flavor

Process Flow Diagram of Juices & nectars

Syrup mixing

↓

Mixing of additives

↓

Lab analysis ← raw juice storage tank

↓

Standardized juice

↓

Balance tank

(UHT‐Flux)

↓

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Pre‐heating

75ºc

↓

De‐aerator

‐0.6 Bar, 72ºc

↓

Final heating 95ºc

↓

Holding sections

(16sec)

↓

Cooling (30ºc)

↓

Storage

Process flow diagram of juices and nectars on pasteurizer

Balance tank

↓

Regeneration 1

35‐40 ºc

↓

Regeneration 2

55‐60 ºc

↓

Heating section

90 ºc

65

↓

Holding section 15 sec

↓

Regeneration 2

75 ºc

↓

Regeneration 1

50‐55 ºc

↓

Cooling section

30‐35 ºc

ASEPTIC PACKAGING

After UHT treatment products are aseptically packed in brick or slim packing by different Tetra Pak

machines.

Composition of aseptic packaging

Paper (70 percent) – provides stiffness, strength and the efficient brick shape

Polyethylene plastic (24 percent)

Forms the seal on the innermost layer that makes the package liquid‐tight and a

protective coating on the exterior keep the package dry.

Aluminum (6 percent) ‐‐ forms a barrier against light and oxygen, eliminating the need for

refrigeration and preventing spoilage without using chemical preservatives.

Benefits of Aseptic Packaging

• Convenience

Aseptic packages are portable, lightweight, and shatterproof and easily transportable

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• Food Safety

The aseptic process and carton together ensure that the liquid food or beverage inside is free from

harmful bacteria and contaminants.

• No refrigeration required

• Long shelf life

Packaging machines

Sr No. Model No. Assigned Brick Size Capacity

1 TBA 8 A 1000 ml 1000 bricks/hr

2 TBA 19 (40V) B 250 ml 7500 bricks/hr

3 TBA 19 (20V) C 250 ml 7500 bricks/hr

4 TBA 19 (30V) D 200 ml 7500 bricks/hr

5 TBA 19 (20V) E 25 0ml 7500 bricks/hr

6 TBA 9 F 250 ml (Juices) 6000 bricks/hr

TBA = TETRA BRIK ASEPTIC

General description of working of Tetra Pak machine

Paper coil section

In this section a reel of packaging material is fitted at the base of machine

Shape creasing roller:

The paper is passed though bending and creasing rollers, which facilitate bending and folding of,

paper later on.

Motor driven roller:

Motor driven rollers which ensures a smooth and safe feeding of packaging material.

Dating section:

It prints the expiry date, machine number on the paper.

Longitudinal seal section:

Poly strip is attached longitudinally at one end of paper by strip applicator.

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Aseptic chamber

Tetra Pak paper is passed through hydrogen per oxide (35%) solution so it become sterilized.

Calendar Rollers:

Rollers which squeeze away surplus H2O2.

Air knife section

Hot air (120‐130ċ) is applied on the paper to evaporate the hydrogen per oxide.

Longitudinal sealing Section

Edges of packaging material are heated with hot sterile air. After the edges are heated, the

packaging material are passed through a forming ring in which LS is sealed by both edges in

packaging material being passed and forming a tubular shape.

LS short stop element

Short stop nozzle for heating the LS at restart after a short stop.

Filling section:

The product is introduced in packaging material. The outlet of filling pipe is under the level of

product which prevents foaming.

Jaws section:

Sealing & cutting of paper is done according to desired shape.

Drop Chute:

It guides the packages into the final folder. It is also used for discharging unusable packages.

Final folder

In final folder packages are given their final shape. The top and bottom flaps are folded in and

sealed to the packages.

Delivery section:

Properly shaped packs are thrown on conveyor.

In case of juices:

After filling of juice in pack it goes for sealing then are conveyed to straw applicator machine

where in a hot chamber plastic blows and gets molded in form of straw then glue sticker sticks the

glue on pack and straw applicator apply straw on it.

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If there is any fault in straw application then straws are separately packed together with juice packs

while tray and shrink packing.

Tests performed in Tetra Pak Section

Longitudinal Sealing (Ink Test)

Transverse Sealing

Conductivity Test

UHT LAB ANALYSIS

In UHT lab all the UHT final products are analyzed by performing different tests

ANALYSIS FOR MILK

pH

Acidity

Taste, color, smell

Fat separation

Sedimentation

ANALYSIS FOR DRINKS

pH

Acidity

Taste, color, smell

°Brix check

ANALYSIS FOR NECTARS

pH

Acidity

Taste, color, smell

°Brix check

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ANALYSIS FOR UHT CREAM

pH

Acidity

ANALYSIS FOR FLAVOURED MILK

pH

Acidity

°Brix

TESTS PERFORMED FOR ENSURING PACKAGING SAFETY:

Three types of test are performed;

1. CONDUCTIVITY TEST

2. INK TEST

3. ZONOSCOPE TEST

4. Weight ability Tests

Why these tests are performed?

To check abnormality in milk

To check packaging faults

To check leakage in pack

1. Conductivity Test:

Cut the upper horizontal side of juice pack like this;

And empty the pack in bucket or in a jar. Dry the empty juice pack completely with towel. Fill

2/3rd of another bucket with water. Take the emptied juice pack and fill water in it until all

seals are dipped in water.

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Place it in bucket facing upward the cut portion. Connect galvanometer with two wires and

then dip one wire in bucket water and other one in pack water. If conductivity circuit

completes then needle of galvanometer shows movement indicating packaging material is

unsafe to use because of any opened pores or holes in packaging material or seal eruption.

2. Ink Test :

A special ink is made by Tetrapack company and is given to food industries using tetrapack

packages to check is seal application is perfectly done or not.

For this injection of ink is inserted in strip made of MPM material and checked if it runs smoothly

along the seal strip then seal is properly applied and sticked to packaging material.

3. Zonoscope Test:

For this test zonoscope is used and it is placed on inner seal strips facing towards light to see

whether seal is broken or not.

4. Weight ability Tests:

This test is performed to the quantity of juices and milk present in packet. If quantity of milk

or juice in a particular packet is more than required than factory will suffer a loss.

Volume Of liquid Standard Weight of liquid+packet

Nector 1000 ml 1065‐1075gm

Milk 1000 ml 1050‐1060 gm

Milk 250 ml 265‐270 gm

Drinks 250ml 258‐263gm

Flavored milk 250 ml 268‐273gm

MICRO LAB ANALYSIS

Why microbial tests are performed?

Microbial tests are performed to check microbial load in rear and front portion of milk tank,on

equipments,environment and in milk itself to avoid milk spoilage.Swab test is performed for

equipment and rear and front portion of milk tank.

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Types of MEDIA used:

4 types of agar Medias are used i.e.

1. Mc Conkey Agar

2. Potato dextrose agar

3. Plate count agar

4.S.S agar

THESE TESTS ARE PERFORMED FOR FOLLOWIN:

1. TPC (total plate count)

2. Ecoli

3. Salmonella and shigella

4. Yeast and mould

5. Coliform

6. Environmental testification

7. Swab testification

EXPLANATION:

i. TPC: Simple agar media is used. First we sterilize all the glass ware in autoclave at 121c and 15

PSI.

MEDIA PREPARATION;

21 g /liter media is prepared in flask and then cover it with aluminum foil and sterilize it in the

autoclave at 121C and 15 PSI pressure after that in aseptic environment under laminate flow

pour the sample in Petri dish for more accuracy sample is diluted.

Dilution:

In a test tube pour 9 ml water and 1 ml sample mix it then take 1 ml sample from it and pour in

petridish and 1ml of sample in 2nd test tube containing 9ml water to form 10‾² dilutuion. And

pour 1 ml of it in petridish.Now the sterilized media is poured on them they are allowed to

solidify and then incubated.

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INCUBATION:

Incubated at 37 ˚C for 24‐48 hr. calculate colonies by colony counter.

RESULT:

∑C/ (n� +0.1n2) d

∑C=Sum of colonies

N�=no of plates from lowest dilution.

N2= no of plates from high dilution.

D=dilution factor of n�

ii. COLIFORM COUNT:

MEDIA: Mackonky agar is used that is of red color about 50g/L and Ph is maintained.

PROCEDURE: Prepare a media in a conical flask then cover it with aluminum foil and autoclave it

at 121˚C for 15 PSI pressure after that pour 1ml of milk sample in sterilized Petri dish and then

inoculated the media on it shake a little and allow it to solidify in aseptic condition and then

incubate for 24 ‐48 hr at 37˚C and count the choliform.

RESULT: If microbes are seen that test +ive.

iii. SALMONEELA SHAGELLA

MEDIA:

S.S agar is used. We dissolve 60g/L and ph is maintained by using 0.1 N ACID OR 0.1 N bases

PROCEDURE:

Prepare a media in a conical flask then cover it with aluminum foil and autoclave it at 121˚C for

15 PSI pressure. After that pour 1ml of milk sample in sterilized Petri dish and then inoculated

the media on it shake a little and allow it to solidify in aseptic condition 24‐48 hr and note

readings.

RESULT: If microbes are seen that test +ve.

iv. YEAST AND MOLD:

MEDIA: Potato dextrose Agar is used about 39g /L AND PH is maintained.

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PROOCEDURE: Prepare a media in a conical flask then cover it with aluminum foil and

autoclave it at 121˚C for 15 PSI pressure. After that pour 1ml of milk sample in sterilized

Petri dish and then inoculated the media on it shake a little and allow it to solidify in

aseptic condition 24‐48 hr and note readings.


v. ENVIOMENTAL CONDITIONS: For environment test media vary if to observe coliform in

environment then Macon key agar is used and for TPC .Plate agar is used.

PROOCEDURE: Prepare a media in a conical flask then cover it with aluminum foil and

autoclave it at 121˚C for 15 PSI pressure. After that pour 1ml of milk sample in sterilized

Petri dish and then allow it to solidify then for 3min expose media to environment after

that incubate it for 24‐48 hr at 37˚C and note readings


vi. SWAB TEST:

25ml water,1cotton plug, desired media

Swab test is done to check microbiology of equipments and all the things that are in

direct contact with food.

PROCEDURE:

Auto clave 25ml water for the purpose of sterilization then make 2 inch cotton swab and

pour in water and dip it until it is socked well then take the cotton out with a sterilize holder

and rub the area to be studied about 1 foot then press cotton in water again. Now take it to

laminar flow of air then pour 1ml of this water on sterilized Petri dish and then pour media

over it. Media is selected according to organism then allow it to solidify then incubate it for

24‐48 hr at 37˚C and note readings


74

Keeping Quality Lab

In Keeping Quality Lab, check the quality of the products throughout their shelf life.

In Keeping Quality Lab:

Four samples and one reference sample of each product at normal shop temperature

condition are placed.

1 First sample is checked after one week of its production

2 Second sample is checked after one month of its production.

3 Third sample is checked at the time of its expiry.

4 Fourth sample is checked after passing half the time of its expiry date.

Incubation Lab

The dairy products like UHT and juices are checked and ensured that there is no microbial

growth in the finished products. For this purpose samples are taken from PLE Hall and

placed in the Incubation Lab at 37 oC for five days.

After five days, the samples are tested that there whether is microbial growth occurs or no

After the five days, the samples of every half an hour of production must be cutoff test its

pH and other physical tests. If the tests are negative then allow the production to sale.

If there is shortage of the product in the market and there is need to dispatch the product

early than five days, then from the stored samples, 1/2 of the packets are cut and test the

pH and perform other physical tests. If the results are negative then the product is

transferred to the distributors but they are not allowed to sale the product. The left half

samples are checked on completing the five days in the Incubation Lab by the same method

previously discussed. After confirming that the product is safe and free from

microorganisms, then allow the distributors to

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Shelf life of products

Name of product

Shelf life of product

Orange juice

Apple nectar

Mango nectar

270 days

Flavored milk 120 days

Apple fruit drinks

Mango fruit drink

Mixed fruit drink

365 days

Plain UHT milk 90 days

UHT cream 120 days

Acidity, pH and °Brix of slim products are shown in following table.

Type of product pH acidity °Brix

Orange juice 3.78 0.46±0.02 13%

Apple nectar 3.28 0.28±0.02 13%

Mango nectar 3.74 0.18±0.02 13%

Mango drink 3.35‐3.38 0.15‐0.16 4%

Apple fruit drink 3.06 0.15 ‐0.16 4%

Mix fruit drink 3.35‐3.38 0.15‐0.16 4%

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pH of different flavored milk are shown in following table

Types of flavored milk ph

strawberry 3.72‐3.78

mango 3.72‐3.78

chocolate 3.72‐3.78

banana 3.72 ‐3.78

ice‐cream 3.72‐3.78

Badam zafran 3.73‐3.78

CLEANING & SANITIZATION:

Cleaning in place (CIP)

CIP stands for cleaning in place. CIP is removal of milk particles and lowering the microbial load in

the production line & in the raw milk tankers by using various types of cleaning agents (acid, base &

water) and temperature.

Before the milk is stored in silos they should be cleaned, so that they can be used without any

hygienic problem. Usually after every 24 hours the silos gone through this process. Sometime if

needed they could be cleaned before 24 hours or after every production.

This process of cleaning of silos takes approximately 120 minutes.

The process includes the following steps.

1 The circuit is made for the desired silo or line.

2 Secondly hot water is circulated for 10 minutes.

3 Then caustic soda is circulated for 15 minutes.

4 In this step, hot water is again circulated for about 15 minutes.

5 In the fifth step, nitric acid is circulated for 15 minutes.

6 Finally hot water is circulated for 15 min which completes the process of CIP.

After this cleaning, the milk is stored in the silos.

Function of Various Cleaning Agents in CIP

Lye is for removal of fat residues and dissolves all the milk particles.

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Acid for the removal of protein matter

Hot water is for the removal of residues and salt.

Acid and hot water also used for lowering microbial load.

Nitric acid also neutralizes the effect of caustic soda

Note: Caustic Soda (NaOH) and Nitric Acid (HNO3) are stored in separate tanks.

Concentrations:

The concentration of Acid and lye used for the CIP is:

1. Lye (NaOH) =1.7 ‐ 2.2 % at 80 ‐ 85°C.

2. Acid (HNO3) = 1 ‐ 1.5% at 70 ‐ 75°C.

3. Water at 80 ‐ 85°C.

Types of CIP:

Two types of CIP are done in the NOON DAIRY

1‐ Short CIP (40 min)

2‐ Long CIP (70 min)

Short CIP:

1) Milk is drained out of tanker or the pipelines and then it is washed with water for 10 min.

2) After this Lye (NaOH) solution of 1.7 ‐ 2.2 % at temperature of 80 – 85° C is circulated in the tank

or lines for 10 minutes.

3) Again tanker is washed with water for 5 min.

4) Then Nitric acid (HNO3) having a concentration of 1 ‐ 1.5% at the temperature 70 ‐ 75°C of is

circulated in the tank or lines for 10 minutes.

5) Again tanker is washed with hot water at 80 – 85° C for 5 min.

Long CIP:

1) After drainage of milk from tanker or the pipelines it is washed with water for 10 min.

2) After this Lye (NaOH) solution of 1.7 ‐ 2.2 % at temperature of 80 – 85° C is circulated in the tank

or lines for 15 minutes.

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3) Again tanker is washed with water for 10 min.

4) Then Nitric acid (HNO3) having a concentration of 1 ‐ 1.5% at the temperature 70 ‐ 75°C of is

circulated in the tank or lines for 15 minutes.

5) Again tanker is washed with hot water at 80 – 85° C for 10 min.

TECHNICAL DATA SHEET

Plant production capacity

Reception + Dairy Processing 3,25,000 Lt/Day

UHT Packing Capacity 2,40,000 Lt/Day

Pasteurizer I 6200 Lt/Day

Pasteurizer II 7200 Lt/Day

Pasteurizer III 15000 Lt/Day

UHT Silo 1 & 2 26,500*2 Lt

UHT Silo 3 30,000 Lt

UHT Silo 4 50,000 Lt

Building

3.5‐ Acre

Total Area

16 Acre

Personnel:

Male: 600

Female ‐

Total staff 600

2

2

BUILDING

Walls Beams, Bricks,

Roof RCC

Floor Acid Resistant Tiles

Windows Aluminium

Doors Aluminium

Partitions Bricks

Walkway Tiles+ Bricks

Drainage Open Drainage in Processing Area

Environment (other buildings, roads,

paved/unpaved surface, possible risks of

pollution, etc)

As described by NEQS (National Environmental

Quality Standards)

RAW MATERIALS

RAW MILK

Purchased from Self‐collection + supplier

Fat % (average) 4.5%

Protein % (average) 3‐4%

WASTE DISPOSAL

Liquid Waste is dispose in nearby sewage canal and solid waste (paper Waste) is sold.

3

3

Suggestions:

Health and safety point of view:

1) Hygiene of workers should be maintained and checked daily.

2) Sanitization of industry should be done and assessed on daily basis.

3) Industry should have its own ambulance.

4) Expert person in first aid should be present round the clock.

Behavioral point of view:

1) Wages of workers should be increased to increase their moral.

2) Appraisal must be done on workers achievement.

3) All workers should be allowed for giving innovative ideas it causes temptation for

increased work efficiency with effectiveness.

4) Workers should be ethically trained to treat each other respectfully.

5) Give no chance for backbiting.

6) Problems of workers should be shared and solved by management as when he

would work with peace of mind will give 100%.

7) Rule of everybody, anybody, somebody and nobody should not be applied, every

person should be responsible.

Improvement point of view:

1) Lab assistants should be provided with thick cotton gloves to handle the apparatus

while performing fat test.

2) Tests must be performed for every sample either raw material or final product.

3) Research and development lab should be upgraded and there must be separate lab

for testing UHT products.

4

4

4) Newly made products should be tested for their harmful effects on human health

before their launching.

5) More scientific lab equipment’s must be purchased to detect the type of adulterant

used it would help to get pure milk.

6) Don’t just go for apparent quality or doing full count of contents go for originality

means to say no masking at all.

7) Different rest rooms and changing rooms must be built separate from working

area.

8) Workers should not be allowed to do tea break in working area.

THANK YOU

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